Reinforced thermoplastic resin composition and molded products thereof

ABSTRACT

The present invention relates to a reinforced thermoplastic resin composition comprising at least an amorphous thermoplastic resin (A), a flame retardant (B), fibrous calcium silicate (C) and an inorganic material (D) comprising talc and/or mica,
         the content of flame retardant (B) being 0.01 to 30 parts by weight based on 100 parts by weight of the amorphous thermoplastic resin (A);   the content of fibrous calcium silicate (C) in said composition being 3 to 30% by weight, and the content of the inorganic material (D) comprising talc, mica or mixture thereof in said composition being 3 to 30% by weight.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/015,446, filed Dec. 16, 2004, now U.S. Pat. No. 7,405,253, whichclaims priority to Japanese Patent Application No. 2003-427965, filedDec. 24, 2003. The contents of these applications are incorporatedherein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a reinforced thermoplastic resincomposition and the molded products thereof. More particularly, itrelates to a reinforced thermoplastic resin composition which canminimize abrasion of the screws and inner walls of cylinders of the meltkneader and the gate and cavity of the mold in the process of productionof the composition and molding, and which causes little warpage of themolded products and also excels in rigidity, strength, self-tappingproperties, flame retardancy, etc., and the molded products of the saidresin composition.

Amorphous reinforced resins are widely used in the various fields ofindustry because of their high degree of design freedom and excellentproductivity, and many methods for incorporating fibrous inorganicreinforcements, plate-shaped or particulate inorganic fillers or such inthe resin compositions for further improvement of strength or rigidityhave been proposed. For instance, Japanese Patent Application Laid-Open(KOKAI) No. 6-172611 discloses a glass-reinforced flame-retardantpolycarbonate resin composition produced by incorporating a flameretardant and glass fibers, glass flakes or glass beads in a resincomposition comprising a polycarbonate resin and an ABS resin. However,the glass fibers, glass flakes and glass beads incorporated in thecomposition described in the above patent are all high in hardness andtherefore cause excessive abrasion of the cylinder inner walls andscrews of the extruder or molder and the gate and cavity of the mold inthe process of production and molding of the resin compositions, so thatit has been difficult to produce with stability a high-qualityglass-reinforced flame-retardant polycarbonate resin composition and themolded products of such a resin composition.

Japanese Patent Application Laid-Open (KOKAI) No. 8-127711 discloses aresin composition comprising a polycarbonate resin, an aromaticpolyester resin, an elastomeric material, surface-treated talc and/orsurface-treated mica, and Japanese Patent Application Laid-Open (KOKAI)No. 8-176339 discloses a resin composition produced by blending talchaving a bulk specific gravity of 0.4 to 0.9 in a thermoplastic resinsuch as polycarbonates. Any of the resin compositions disclosed in thesepatents is indeed improved in rigidity and warpage in its own way andcan lessen abrasion of the screws and cylinders of the melt kneader andmolder and the gate and cavity of the mold, but these resin compositionsare unsuited for the production of the molded articles which requireclamping by self-tapping screws, because these resin compositions cannot provide enough self-tapping strength, and thus there were of poorpractical applicability.

In Japanese Patent Application Laid-Open (KOKAI) No. 8-073728 disclosesa resin composition produced by blending a fibrous inorganic filler suchas wollastonite (fibrous calcium silicate) in a polycarbonate resin or amixture thereof with other thermoplastic resin. Japanese PatentApplication Laid-Open (KOKAI) No. 2000-230124 discloses a thermoplasticresin composition comprising a mixture of a thermoplastic resin such aspolycarbonates and fibrous β-wollastonite which has been surface-treatedwith a phosphoric ester compound. Further, Japanese Patent ApplicationLaid-Open (KOKAI) No. 2002-265769 discloses a resin composition obtainedby blending wollastonite of a specific particle shape in a resin basecomprising a polycarbonate resin or such. The resin compositionsdisclosed in these patents, however, can provide only those moldedproducts which, although improved in rigidity and self-tapping strength,have high anisotropism and a large warpage because of incorporation offibrous wollastonite.

SUMMARY OF THE INVENTION

The object of the present invention is to provide a reinforcedthermoplastic resin composition which can lessen abrasion of thecylinder inner walls, screws, etc., of the melt kneader and molder andthe gate and cavity of the mold in the process of production and moldingof the resin composition, and which causes little warpage of the moldedproducts and also excels in rigidity, strength, self-tapping properties,flame retardancy, etc., and the molded products obtained from the saidresin composition.

As a result of the present inventors' earnest studies on the subjectmatter, it has been found that it is possible to realize both reducedwarpage of the molded products and improvement of self-tapping strengthat the same time by containing specified amounts of a flame retardant,fibrous calcium silicate, talc, mica or mixture thereof in an amorphousthermoplastic resin, and consequently to obtain a thermoplastic resincomposition which excels in all of the said points and has a goodbalance of properties, and the molded products comprising thiscomposition.

In the first aspect of the present invention, there is provided areinforced thermoplastic resin composition comprising at least (A) anamorphous thermoplastic resin, (B) a flame retardant, (C) fibrouscalcium silicate, and (D) an inorganic material comprising talc, mica ormixture thereof, the content of the flame retardant (B) in ratio basedon 100 parts by weight of the amorphous thermoplastic resin (A) being0.01 to 30 parts by weight, the content of fibrous calcium silicate (C)in the said composition being 3 to 30% by weight, and the content of theinorganic material (D) comprising talc, mica or mixture thereof in thecomposition being 3 to 30% by weight.

In the second aspect of the present invention, there are provided themolded products comprising the above reinforced thermoplastic resincomposition.

DETAILED DESCRIPTION OF THE INVENTION

A detailed description of the present invention is given below.

As the amorphous thermoplastic resin (A) used in the present invention,for example, polycarbonate resins, polyphenylene ether resins,polystyrene resins, polysulfone resins, polyethersulfone resins,polyetherimide resins, polyallylates and PMMA can be mentioned. Of theseresins, polycarbonate resins, polyphenylene ether resins and polystyreneresins are preferred, polycarbonate resins and polyphenylene etherresins being especially preferred in view of having a good balance ofheat resistance, flame retardancy and moldability.

“Polycarbonate resin” referred to in the present invention is a mixtureof 50 to 100% by weight of a polycarbonate resin and 50 to 0% by weightof other thermoplastic resin. 100% by weight of polycarbonate resin isalso possible. As other thermoplastic resin used in combination with apolycarbonate resin, AS resins, ABS resins, polyethylene terephthalate,polybutyrene terephthalate, etc., are usable, of which AS resins and ABSresins are preferred. The content of other thermoplastic resin in ratiobased on 100% by weight of polycarbonate resin is preferably not morethan 50% by weight, more preferably not more than 40% by weight. Whenits content exceeds 50% by weight, deflection temperature under load ofthe composition may lower. In terms of heat resistance and flameretardancy, it is preferable that the content of other thermoplasticresin be minimized, but a higher content of other thermoplastic resin ispreferred for better fluidity of the composition. Considering theseconflicting factors, the upper limit of the content of otherthermoplastic resin is especially preferably 10% by weight while itslower limit is usually 30% by weight.

The polycarbonate resin used in the present invention may be selectedfrom aromatic polycarbonate resins, aliphatic polycarbonate resins andaromatic-aliphatic polycarbonate resins, but aromatic polycarbonateresins are preferred in view of heat resistance and flame retardancy.Exemplary of such aromatic polycarbonate resins are the thermoplasticaromatic polycarbonate polymers or copolymers, including the branchedones, made by reacting aromatic hydroxyl compounds or these compoundsand a small quantity of polyhydroxyl compounds with phosgene or carbonicdiesters.

As the said aromatic dihydroxyl compound,2,2-bis(4-hydroxyphenyl)propane (=bisphenol A), tetramethylbisphenol A,bis(4-hydroxyphenyl)-p-diisopropylbenzene, hydroquinone, resorcinol,4,4′-dihydroxybiphenyl and such can be used, with bisphenol A beingpreferred. In order to further enhance flame retardancy, it is possibleto use the compounds having one or more tetraalkylphosphonium sulfonatesattached to the said aromatic dihydroxyl compounds, and/or the polymersor oligomers having a siloxane structure and containing phenolic OHgroups at both ends of the molecular chain.

For obtaining a branched aromatic polycarbonate resin, a polyhydroxylcompound such as phloroglucin,4,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-2,4,6-dimethyl-2,4,6-tri(˜4-hydroxyphenyl)heptane,2,6-dimethyl-2,4,6-tri(4-hydroxyphenyl)heptene-3,1,3,5-tri(4-hydroxyphenyl)benzene,or 1,1,1-tri(4-hydroxyphenyl)ethane, etc., or3,3-bis(4-hydroxyaryl)oxyindole (=isatinbisphenol),5-chloroisatinbishphenol, 5,7-dicycloisatinbisphenol,5-bromoisatinbisphenol or the like is used as a part of the saidaromatic dihydroxyl compound. This additive compound is used in anamount of usually not less than 0.01 mol %, preferably not less than 0.1mol %, but usually not more than 10 mol %, preferably not more than 2mol % in the aromatic dihydroxyl compound.

An aromatic monohydroxyl compound is used for adjusting the molecularweight. Exemplary of such an aromatic monohydroxyl compound arem-methylphenol, p-methylphenol, m-propylphenol, p-propylphenol,p-tert-butylphenol, and p-long-chain alkyl-substituted phenol.

Particularly preferred for use as the polycarbonate resin in the presentinvention are the polycarbonate polymers derived from2,2-bis(4-hydroxyphenyl)propane, and the polycarbonate copolymersderived from 2,2-bis(4-hydroxyphenyl)propane and other aromaticdihydroxyl compounds.

In case where the amorphous thermoplastic resin (A) used in the presentinvention is a polycarbonate resin, this polycarbonate resin maycomprise two or more types of polycarbonate resin.

The molecular weight of the said polycarbonate resin, determined asviscosity-average molecular weight from the solution viscosity measuredat 25° C. using methylene chloride as solvent, is usually not less than14,000, preferably not less than 15,000, more preferably not less than16,000, but usually not more than 30,000, preferably not more than28,000, more preferably not more than 26,000. When the viscosity-averagemolecular weight of the polycarbonate resin is less than 14,000, thecomposition may not be provided with satisfactory mechanical strength,while when the above viscosity exceeds 30,000, the composition tends tohave a problem in moldability.

The preparation method of the polycarbonate resin is not specificallydefined; it is possible to produce the resin by, for example, phosgenemethod (interfacial polymerization method) or melting method (esterexchange method). It is also possible to use an aromatic polycarbonateresin produced by the melting method and adjusted in the amount of itsterminal OH groups.

The polyphenylene ether resin used in the present invention comprises 30to 100% by weight of a polyphenylene ether resin and 70 to 0% by weightof other thermoplastic resin. A polyphenylene ether resin may be usedalone. As other thermoplastic resin used in combination with apolyphenylene ether resin, polystyrene resins are preferred in terms ofcompatibility with polyphenylene ether resins. When the ratio of otherresin exceeds 70% by weight based on 100% by weight of polyphenyleneether resin, the composition may be reduced in deflection temperatureunder load. The content of other resin is more preferably not more than50% by weight, with its lower limit being preferably around 10% byweight.

The polyphenylene ether resin used in the present invention is usually ahomopolymer or a copolymer having a structure (repeating unit)represented by the following formula (1):

wherein Q¹s represent independently a halogen atom, a primary orsecondary alkyl group, an aryl group, an aminoalkyl group, an alkoxylgroup or a haloalkoxyl group; Q²s represent independently a hydrogenatom, a halogen atom, a primary or secondary alkyl group, an aryl group,a haloalkyl group, an alkoxyl group or a haloalkoxyl group; and m is aninteger of 10 or more.

In the above formula (1), when Q¹ is a halogen atom, it is preferablychlorine atom or bromine atom.

When Q¹ is a primary alkyl group, it is preferably an alkyl group having1 to 10 carbon atoms such as methyl, ethyl, n-propyl, n-butyl, n-amyl,isoamyl, 2-methylbutyl, n-hexyl, 2,3-dimethylbutyl, 2-, 3- or4-methylpentyl or heptyl.

When Q¹ is a secondary alkyl group, it is preferably an alkyl grouphaving 4 to 10 carbon atoms such as isopropyl, sec-butyl or1-ethylpropyl.

When Q¹ is an aryl group, its preferred example is phenyl, and when itis an aminoalkyl group, it is preferably the one having an alkyl chainwith about 1 to 5 carbon atoms, such as dimethylamino, diethylamino anddibutylamino.

When Q¹ is an alkoxyl group, it is preferably selected from thosecorresponding to the groups cited above as preferred examples of alkylgroup. When Q¹ is a haloalkoxyl group, examples thereof are those of thesaid alkoxyl groups in which one or more of the hydrogen atoms aresubstituted with a halogen atom.

In the above formula (1), Q²s represent independently a hydrogen atom, ahalogen atom, a primary or secondary alkyl group, an aryl group, ahaloalkyl group, an alkoxyl group or a haloalkoxyl group. When Q² is ahalogen atom, a primary or secondary alkyl group, an aryl group, analkoxyl group or a haloalkoxyl group, the preferred examples thereof arethe same groups as mentioned above with relation to Q¹. When Q² is ahaloalkyl group, its preferred examples are those of the groupsmentioned above as preferred examples of alkyl group in which one ormore hydrogen atoms are substituted with a halogen atom.

In the above formula (1), Q¹ is preferably an alkyl group or a phenylgroup, especially an alkyl group having 1 to 4 carbon atoms. Q² isespecially preferably a hydrogen atom.

Preferred examples of the polyphenylene ether resin homopolymers arethose comprising the repeating units derived from2,6-dimethyl-1,4-phenylene ether (satisfying the specifications of theabove formula (1)). Preferred examples of the copolymers are the randomcopolymers comprising a combination of the said repeating units andthose derived from 2,3,6-trimethyl-1,4-phenylene ether (satisfying thespecifications of the above formula (1)).

For adjusting the molecular weight or improving the various propertiessuch as melt viscosity and/or impact strength within limits notaffecting the normal performance of the present invention, it is alsopreferable to use polyphenylene ethers having a repeating structureother than the one represented by the above formula (1).

The polyphenylene ether resin used in the present invention ispreferably the one whose intrinsic viscosity measured in chloroform at30° C. is 0.2 to 0.8 dl/g, more preferably 0.2 to 0.7 dl/g, especially0.25 to 0.6 dl/g. When the intrinsic viscosity of the resin is less than0.2 dl/g, the produced composition may prove poor in impact resistance,and when the viscosity is over 0.8 dl/g, moldability of the compositionmay be found unsatisfactory.

The polystyrene resins usable as amorphous thermoplastic resin (A) inthe present invention are the polymers or copolymers containing not lessthan 50% by weight of the repeating units derived from the aromaticvinyl compounds, or the rubber-modified version of these polymers orcopolymers.

Examples of the said aromatic vinyl compounds are styrenes;α-alkyl-substituted styrenes such as α-methylstyrene; and nuclearalkyl-substituted styrenes such as p-methylstyrene, o-ethylstyrene,vinyltoluene and o-p-dichlorostyrene.

As the monomers other than the aromatic vinyl compounds, the followingcan be mentioned: vinyl cyanate compounds such as acrylonitrile,methacrylonitrile and ethacrylonitrile; (meth)acrylic ester compoundssuch as methyl, ethyl, propyl, n-butyl, and n-hexyl, etc. of acrylic andmethacrylic acids; maleimide and maleimide compounds such asN-methylmaleimide, N-cyclohexylmaleimide and N-phenylmaleimide;acrylamide and acrylamide compounds such as N-methylacrylamide;unsaturated acid anhydrides such as maleic anhydride and itaconicanhydride; unsaturated acids such as acrylic acid and methacrylic acid;and various other vinyl compounds such as glycidyl acrylate, glycidylmethacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate andmethoxypolyethylene glycol methacrylate. Typical examples of the saidpolystyrene resins are polystyrene, AS (acrylonitrile-styrene) resin andMS (methyl methacrylate-styrene) copolymer.

The weight-average molecular weight of these polystyrene resins (theabove-mentioned polymers) is usually not less than 50,000, preferablynot less than 100,000, more preferably not less than 150,000, butusually not more than 500,000, preferably not more than 400,000, morepreferably not more than 300,000.

The polystyrene resins used in the present invention may be therubber-modified version of the said polymers. As rubber formodification, polybutadiene, styrene-butadiene copolymer, polyisoprene,ethylene-propylene copolymer and the like, can be used. Examples of therubber-modified version of the said polymers are high impactpolystyrenes, ABS resins, MBS resins, or AES resins, etc.

The ABS resins in the present invention include, besidestyrene-butadiene-acrylonitrile copolymer (ABS resin), those of the ABSresins in which the rubber moiety mainly comprised of butadiene issubstituted with other type of rubber such as ethylene-propylene rubberand acrylic rubber, etc. as well as those in which styrene and/oracrylonitrile are substituted with other monomers.

Especially preferred as polystyrene resin in the present invention arepolystyrenes, rubber-modified version of the polystyrene resins andmixtures thereof.

The flame retardant (B) used in the present invention is notspecifically defined; it is possible to use the ones known in the art,preferably phosphoric ester compounds, organosulfonic acid metal saltsand silicone compounds. Phosphoric ester compounds are particularlypreferred in view of improvement of fluidity.

The phosphoric ester compounds usable in the present invention include,for example, those represented by the following formula (2):

wherein R¹, R², R³ and R⁴ represent independently an aryl group whichmay be substituted; X represents an arylene group which may besubstituted; and n is an integer of 0 to 5.

As the aryl group represented by R¹ to R⁴ in the above formula (2),phenyl group and naphthyl group can be mentioned as examples. Thearylene groups represented by X include phenylene group, naphthylenegroup, and the divalent groups derived from the bisphenol compounds. Thesubstituent groups that these aromatic rings can possess include alkylgroups having about 1 to 8 carbon atoms, alkoxyl groups having about 1to 8 carbon atoms, and hydroxyl groups. The compound represented by theabove formula (2) is a phosphoric ester when n is 0, and a condensedphosphoric ester (a mixture) when n is 1 or more.

The condensed phospholic ester compounds (n is 1 or more) are preferablyused in the present invention. Exemplary of the compounds represented bythe above formula (2) are bisphenol A bisphosphate, hydroquinonebisphosphate, resorcinol bisphosphate, and their substituents orcondensates.

The commercially available condensed phosphoric ester compounds areunder the trade names of, for example, “CR733S” (resorcinolbis(diphenylphosphate)) and “CR741” (bisphenol Abis(diphenylphosphate)), both being supplied from Daihachi ChemicalIndustry Co., Ltd., and “FP500” (resorcinol bis(dixylenylphosphate))supplied from Asahi Denka Co., Ltd.

In the present invention, the content of the phosphoric ester compoundused as flame retardant (B) is usually not less than one part by weight,preferably not less than 3 parts by weight, more preferably not lessthan 5 parts by weight, but usually not more than 30 parts by weight,preferably not more than 25 parts by weight, more preferably not morethan 20 parts by weight, based on 100 parts by weight of the amorphousthermoplastic resin (A). When the content of the phosphoric estercompound is below the lower limit value, flame retardancy of thecomposition may fall short of being satisfactory, and when the contentexceeds the upper limit value, heat resistance may deteriorate.

The organosulfonic acid metal salts used in the present invention may beeither aliphatic or aromatic. Alkaline or alkaline earth metals arepreferably used as the metal moiety of the organosulfonic acid metalsalts. Examples of such metals are sodium, lithium, potassium, rubidium,cesium, beryllium, magnesium, calcium, strontium and barium, of whichsodium and potassium are preferred in view of flame retardancy. Two ormore of the organosulfonic acid metal salts may be used in combination.

The aliphatic sulfonates used in the present invention are preferablyfluoroalkane-sulfonic acid metal salts, more preferablyperfluoroalkane-sulfonic acid metal salts. Preferred examples of thefluoroalkane-sulfonic acid metal salts are alkaline metal salts andalkaline earth metal salts of fluoroalkane-sulfonic acid. More preferredare alkaline metal salts and alkaline earth metal salts offluoroalkane-sulfonic acid with a carbon number of 4 to 8

Examples of the fluoroalkane-sulfonates include sodiumperfluorobutane-sulfonate, potassium perfluorobutane-sulfonate, sodiumperfluoromethylbutane-sulfonate, potassiumperfluoromethylbutane-sulfonate, sodium perfluorooctane-sulfonate,potassium perfluorooctane-sulfonate, and tetraethylammonium salt ofperfluorobutane-sulfonic acid.

As preferred examples of the aromatic sulfonic acid metal salts usablein the present invention, aromatic sulfonic acid alkaline metal salts,aromatic sulfonic acid alkaline earth metal salts, aromaticsulfonesulfonic acid alkaline metal salts, and aromatic sulfonesulfonicacid alkaline earth metal salts can be mentioned. The aromaticsulfonesulfonic acid alkaline metal salts and aromatic sulfonesulfonicacid alkaline earth metal salts may be polymers.

Examples of the aromatic sulfonic acid metal salts are sodium3,4-dichlorobenzenesulfonate, sodium 2,4,5-trichlorobenzenesulfonate,sodium benzenesulfonate, sodium salt of diphenylsulfone-3-sulfonic acid,potassium salt of diphenylsulfone-3-sulfonic acid, sodium salt of4,4′-dibromodiphenyl-sulfone-3-sulfonic acid, potassium salt of4,4′-dibromodiphenyl-sulfone-3-sulfonic acid, potassium salt of4-chloro-4′-nitrodiphenylsulfone-3-sulfonic acid, disodium salt ofdiphenylsulfone-3,3′-disulfonic acid, and dipotassium salt ofdiphenylsulfone-3,3′-disulfonic acid.

The content of the organosulfonic acid metal salt in the composition ofthe present invention is usually not less than 0.01 part by weight,preferably not less than 0.02 parts by weight, more preferably not lessthan 0.03 parts by weight, but usually not more than 30 parts by weight,preferably not more than 5 parts by weight, more preferably not morethan 3 parts by weight, especially preferably not more than 2 parts byweight, based on 100 parts by weight of the amorphous thermoplasticresin (A). When the content of the organosulfonic acid metal salt isbelow the lower limit, the desired level of flame retardancy can hardlybe obtained, and when the said content exceeds the upper limit, thecomposition tends to lose thermal stability.

As the silicone compound used as flame retardant in the presentinvention, organopolysiloxanes having a linear or branched molecularstructure are preferred. The organic group in the saidorganopolysiloxanes is selected from alkyl groups which may havesubstituents with a carbon number of 1 to 20, alkenyl groups which mayhave substituents with a carbon number of around 2 to 20, cycloalkylgroups with a carbon number of around 3 to 20, and aromatic hydrocarbongroups with a carbon number of around 6 to 20 such as phenyl and benzylgroups. Examples of the substituents that the said alkyl and alkenylgroups may have are C₁-C₂₀ alkyl groups, C₁-C₂₀ alkoxyl groups andC₆-C₂₀ aromatic hydrocarbon groups.

Also, polydiorganosiloxanes may have a functional group. Such afunctional group is preferably methacryl group, alkoxyl group or epoxygroup.

The content of the silicone compound is usually not less than 0.2 partsby weight, preferably not less than 0.3 parts by weight, more preferablynot less than 0.4 parts by weight, but usually not more than 30 parts byweight, preferably not more than 5 parts by weight, more preferably notmore than 4.5 parts by weight, especially preferably not more than 4.0parts by weight, based on 100 parts by weight of the amorphousthermoplastic resin (A). When the amount of the silicone compoundcontained is below the lower limit, the finally obtained reinforcedthermoplastic resin composition may prove unsatisfactory in flameretardancy, and when the silicone resin content exceeds the upper limitvalue, heat resistance of the obtained composition may be too low.

In the present invention, it is possible to use either only one flameretardant or two or more different types of flame retardants at the sametime. The total content of the flame retardant(s) is 0.01 to 30 parts byweight, preferably not less than 0.02 parts by weight, more preferablynot less than 0.03 parts by weight, but preferably not more than 25parts by weight, more preferably not more than 20 parts by weight, basedon 100 parts by weight of the resin (A). When the flame retardantcontent is below the lower limit, the obtained composition may beunsatisfactory in flame retardancy, while use of the flame retardant(s)in excess of the upper limit may lead to a reduction of heat resistanceand/or thermal stability of the composition.

In the present invention, it is also possible to contain a fluorineresin for the purpose of preventing dripping during combustion.

The “fluorine resin” mentioned above refers to the polymers or copolymerhaving a fluoroethylene structure, for example, difluoroethylenepolymer, tetrafluoroethylene polymer,tetrafluoroethylene-hexafluoropropylene copolymer, and copolymers oftetrafluoroethylene and fluorine-free ethylene monomers.Polytetrafluoroethylene (PTFE) is preferred. The average molecularweight of the fluorine resin used in the present invention is preferablynot less than 500,000, more preferably 500,000 to 10,000,000. Aspolytetrafluoroethylene, it is possible to use any of the polymerscommonly used in the art for the same purpose as the composition of thepresent invention.

Even higher melt dripping preventive effect can be obtained by usingthose of the polytetrafluoroethylenes which have the fibril-formingproperties. The polytetrafluoroethylenes having the fibril-formingproperties are not specifically defined. Exemplary thereof are thoseclassified under Type 3 in the ASTM standard, which include, forexample, such commercial products as Teflon 6-J (Mitsui Du PontFluorochemical Co., Ltd.), Polyflon D-1, Polyflon F-103 and Polyflon 201(Daikin Industries, Ltd.), and CD076 (Asahi ICI Fluoropolymers Co.,Ltd.).

Among other examples than those classified under Type 3 mentioned aboveare Algoflon F5 (Montefluos Co., Ltd.), and Polyflon MPA and PolyflonFA-100 (Daikin Industries, Ltd.). These polytetrafluoroethylenes may beused either alone or as a combination of two or more types. Thepolytetrafluoroethylenes having the fibril-forming properties can beobtained, for example, by polymerizing tetrafluoroethylenes in anaqueous solvent in the presence of sodium, potassium and ammoniumperoxydisulfide under a pressure of 1 to 100 psi at 0 to 200° C.,preferably 20 to 100° C.

The polyfluoroethylene content is usually 0.01 to 5 parts by weightbased on 100 parts by weight of the amorphous thermoplastic resin (A).When the polyfluoroethylene content is less than 0.01 part by weight,the desired flame-retardancy (dripping preventive effect) may not beobtained, and when the content exceeds 5 parts by weight, the productappearance tends to be impaired. The polyfluoroethylene content ispreferably not less than 0.02 parts by weight, more preferably not lessthan 0.05 parts by weight, but preferably not more than 4 parts byweight, more preferably not more than 3 parts by weight, based on 100parts by weight of the amorphous thermoplastic resin (A).

Fibrous calcium silicate (C) used in the present invention can be, forinstance, wollastonite represented by CaO.SiO₂ or xonotlite representedby 6CaO.6SiO₂.H₂O. Wollastonite is a naturally occurring white acicularcrystalline mineral which is fibrous or lump-formed. In the presentinvention, fibrous wollastonite is preferably used. It is also possibleto use a synthetic product. Fibrous wollastonite is varied in aspectratio depending on the pulverization method and the place of production,but generally β-type wollastonite having a large aspect ratio ispreferred because of high reinforcing performance. The initial fiberdiameter of wollastonite is, on the average, preferably not less than 2μm, more preferably not less than 3 μm, especially preferably not lessthan 4 μm, but preferably not more than 30 μm, more preferably not morethan 20 μm, especially preferably not more than 15 μm. When the averagefiber diameter is less than 2 μm, the fibers are apt to break duringworking, and when it exceeds 30 μm, the reinforcing effect is small.

The initial fiber length of wollastonite is, on the average, preferablynot less than 20 μm, more preferably not less than 25 μm, especiallypreferably not less than 30 μm, but preferably not more than 400 μm,more preferably not more than 300 μm, especially preferably not morethan 250 μm. When the average fiber length is less than 20 μm, thereinforcing effect is small, and when it exceeds 400 μm, the fibers areapt to break during working.

Further, the value obtained by dividing the initial average fiber lengthby the initial fiber diameter (initial average aspect ratio) ispreferably not less than 4 but not more than 50, more preferably notless than 5 but not more than 40, especially preferably not less than 6but not more than 30. When the average aspect ratio is less than 4, thereinforcing effect is small, and when this ratio exceeds 50, the fiberstend to break during working.

Regarding xonotlite which is an example of fibrous calcium silicate (C)used in the present invention, there have already been synthesized thepreparations having an average fiber diameter of 0.5 to 1 μm, an averagefiber length of 2 to 5 μm and an aspect ratio of about 2 to 15. In thepresent invention, it is preferable to use a preparation having thelargest possible aspect ratio (not less than 6) as such a preparationhas an excellent effect of improving mechanical properties and heatresistance (resistance to thermal deformation).

Talc (D) used in the present invention is pulverized and classifiednatural talc having a compositional formula of 3MgO.4SiO₂.H₂O. Theaverage grain size of talc (D) is not specifically defined, but it isusually not less than 0.5 μm, preferably not less than 1.0 μm, morepreferably not less than 1.5 μm, usually not more than 20 μm, preferablynot more than 15 μm, more preferably not more than 10 μm. When theaverage grain size of talc is less than 0.5 μm, its reinforcing effectis small and there is fear of causing large deformation or warpage ofthe product. When the grain size exceeds 20 μm, self-tapping propertiesof the product tend to deteriorate.

Mica (D) used in the present invention is a mineral of the aluminumsilicate system. There are known various types of mica such as thoserepresented by the following chemical formulae: KAl₂(AlSi₃O₁₀)(OH)₂(white mica), K(Mg,Fe)₃(AlSi₃O₁₀)(OH)₂ (black mica), KMg₃(AlSi₃O₁₀)(OH)₂(gold mica), KLi₂Al(Si₄O₁₀)(OH)₂ (flake mica), NaAl₂(AlSi₃O₁₀)(OH)₂(soda mica), and KMg₃(AlSi₃O₁₀)F₂ (fluoro-gold mica), and all of thesemica varieties have a tendency for cleavage. In the present invention,white mica and gold mica are preferred for the improvement of rigidity.In view of rigidity, improvement of warpage and self-tapping propertiesof the resin composition, mica (D) used in the present invention is ofan average grain size of preferably not less than 3 μm, more preferablynot less than 5 μm, especially preferably not less than 10 μm, butpreferably not more than 200 μm, more preferably not more than 150 μm,especially preferably not more than 100 μm. When the average grain sizeof mica is less than 3 μm, the reinforcing effect is small and largedeformation or warpage of the product may take place, and when mica hasan average grain size in excess of 200 μm, self-tapping properties ofthe product tends to deteriorate.

Talc is preferred from the view of cost and mica is preferred from theview of rigidity.

Fibrous calcium silicate (C) and talc and/or mica (D) used in thepresent invention may have been surface treated with various types ofcoupling agent for the purpose of enhancing affinity for the amorphousthermoplastic resin (A) or interfacial bonding force. As the couplingagent, usually silane type, chromium type and titanium type are used.Preferred among them are the silane coupling agents, for example,epoxysilanes such as γ-glycidoxypropyltrimethoxysilane;vinyltrichlorosilane; and aminosilanes such asγ-aminopropyltriethoxysilane. In this case, it is preferable for theimprovement of mechanical strength and kneading properties to conduct atthe same time a treatment with various surfactants including nonionic,cationic and anionic types or dispersing agents such as fatty acids,metallic soap and various types of resins.

The reinforced thermoplastic resin composition according to the presentinvention contains at least an amorphous thermoplastic resin (A), aflame retardant (B), fibrous calcium silicate (C) and an inorganicmaterial (D) comprising talc and/or mica, wherein the content of flameretardant (B) is 0.01 to 30 parts by weight based on 100 parts by weightof the amorphous thermoplastic resin (A), the content of fibrous calciumsilicate in the composition is 3 to 30% by weight and the content of theinorganic material (D) comprising talc and/or mica in the composition is3 to 30% by weight.

In the reinforced thermoplastic resin composition of the presentinvention, when the content of fibrous calcium silicate (C) is less than3% by weight, self-tapping properties and rigidity of the product mayfall short of the intended levels, and when the (C) content exceeds 30%by weight, there is a possibility that the product would become subjectto a large warpage. Also, in the said composition, when the content ofinorganic material (D) comprising talc and/or mica is less than 3% byweight, there is a possibility that the product would become subject toa large warpage, and when the (D) content exceeds 30% by weight,self-tapping strength of the product may lower.

The present invention has realized both reduction of warpage of themolded products and improvement of their self-tapping strength bycontaining in a base resin composition the specified amounts ofcomponents (C) and (D) which have the mutually contradictory effects,and as a consequence, made it possible to provide a reinforcedthermoplastic resin composition having a good balance of properties.

The ratio by weight of fibrous calcium silicate (C)/inorganic material(D) comprising talc and/or mica is in the range from 1/10 to 10/1,preferably from 1/6 to 6/1, especially 1/4 to 4/1.

When the ratio of fibrous calcium silicate (C) is below theabove-defined range, self-tapping properties and rigidity of the productdeteriorate. Conversely, when the ratio of inorganic material (D)comprising talc and/or mica is below the above range, warpage of theproduct is stepped up.

The combined amount of amorphous thermoplastic resin (A) and flameretardant (B) accounts for preferably 50 to 90% by weight of thereinforced thermoplastic resin composition of the present invention.When the combined amount of (A) and (B) is less than 50% by weight,there is a tendency for fluidity of the composition to lower, and whenthis amount exceeds 90% by weight, the composition may lack requiredstrength and rigidity.

The reinforced thermoplastic resin composition of the present inventionmay contain, in addition to the said components, an elastomer forenhancing impact strength within limits not prejudicial to the effect ofthe present invention. The elastomer used in the present invention isnot designated; it is possible to use various known elastomers.

It is also possible to add where necessary stabilizers such asultraviolet absorber and antioxidant, additives such as pigment, dye,lubricant, mold-release agent, antistatic agent, fluidity improver,etc., and reinforcing agents such as whiskers of potassium titanate,aluminum borate, etc., within limits not impairing the effect of thepresent invention.

For obtaining the thermoplastic resin composition of the presentinvention, the following methods, for instance, can be used: the saidcomponent materials are kneaded by various kneading machines such assingle or multiple screw kneader, Banbury mixer, roll mixer, Brabenderplastogram, etc., then cooling and solidifying the mixture; the saidcomponent materials are added to a proper solvent, for example, ahydrocarbon such as hexane, heptane, benzene, toluene or xylene or aderivative thereof, to form a solution in which the soluble componentsare mixed with each other or the soluble components and insolublecomponents are mixed in a suspended state. The melt kneading method ispreferred in terms of industrial cost, but this method is notdefinitive.

In melt kneading, it is preferable to use a single- or twin-screwextruder, particularly a twin-screw extruder, and feed fibrous calciumsilicate (C) at a point halfway of extrusion. This method enablesstabilized production of the composition while preventing shattering offibrous calcium silicate (C).

Various methods are available for obtaining the molded products from thereinforced thermoplastic resin composition of the present invention. Itis possible, for instance, to apply the molding methods generally usedfor molding of the thermoplastic resin compositions, such as injectionmolding, blow molding, extrusion molding, sheet molding, hot molding,rotary molding and laminate molding. Injection molding is preferred forobtaining a molded product having a cylindrical boss as described later.Cylindrical boss is a useful joining means as it can be easily joined bydirectly driving a metal screw into the cylindrical boss. “Self-tappingproperties” are a measure of structural strength observed when a metalscrew is directly driven into the cylindrical boss, and it can beevaluated by the torque (breaking torque) at which the boss is brokenwhen a metal screw is driven thereinto.

The reinforced thermoplastic resin composition of the present inventionhas excellent self-tapping properties, and its advantage can be put togood use more effectively when the composition is applied to the moldingof the articles having such cylindrical bosses.

Breaking torque is variable depending on the type and configuration ofthe metal screw and the dimension of the boss, but in the case of thereinforced thermoplastic resin composition of the present invention, thebreaking torque observed when, for instance, a B tightening screw with anominal size of 4 mm in diameter and 8 mm in length was driven into aboss measuring 3.5 mm in inner diameter, 2.5 mm in wall thickness and 10mm in height is preferably not less than 1.0 N·m, more preferably notless than 1.5 N·m.

The reinforced thermoplastic resin composition of the present inventionand the molded products thereof can be obtained with stabilized qualitysince abrasion of the cylinder inner walls and screws of the meltkneader and molder and the gate and cavity of the mold used in theproduction and molding of the resin composition is minimized. Also, asthe molded products of the said composition are small in warpage andexcel in rigidity, strength, self-tapping properties, flame retardancy,etc., they can be ideally used as, for example, chassis for electric andelectronic apparatus, OA equipment, etc.

EXAMPLES

The present invention will be described in further detail with referenceto the examples thereof which are not intended to be limitative to thescope of the invention.

(A-1) Polycarbonate resin: poly-4,4-isopropylidenediphenyl carbonate,product of Mitsubishi Engineering-Plastics Corporation, under the tradename of Iupilon S-3000, viscosity-average molecular weight: 21,000(hereinafter abbreviated as PC).

(A-2) Polyphenylene ether resin: poly(2,6-dimethyl-1,4-phenylene ether)(product of Mitsubishi Engineering-Plastics Corporation; intrinsicviscosity measured in 30° C. chloroform: 0.40 dl/g).

(A-3) AS resin: acrylonitrile-styrene copolymer, product of m TechnoPolymer Co., Ltd. under the trade name of SAN-C (molecular weight:150,000).

(A-4) ABS resin: acrylonitrile-butadiene-styrene copolymer, product ofNIPPON A&L INC. under the trade name of SANTAC UT61.

(A-5) Polystyrene resin: polystyrene, product of PS Japan Co., Ltd.under the trade name of HF77 (molecular weight: 220,000).

(B-1) Phosphoric ester compound: resorcinol bis(diphenylphosphate),product of Daihachi Chemical Industry Co., Ltd. under the trade name ofCR733S.

(B-2) Phosphoric ester compound: bisphenol A bis(diphenylphosphate),product of Daihachi Chemical Industry Co., Ltd. under the trade name ofCR741.

Fluorine resin: polytetrafluoroethylene, product of Daikin Industries,Ltd. under the trade name of Polyflon F-201L (molecular weight:5,000,000).

(C) Fibrous calcium silicate: wollastonite having an average fiberdiameter of 8 μm and an average fiber length of 136 μm (average aspectratio: 17), product of Naiko Co., Ltd. under the trade name of Naigloss8.

(D-1) Mica: white mica having an average grain size of 40 μm, product ofYamaguchi Mica CO., LTD. under the trade name of A-41.

(D-2) Mica: gold mica having an average-grain size of 30 μm, product ofKuraray Co., Ltd. under the trade name of 325HK.

(D-3) Talc: talc having an average grain size of 2 μm, product ofHayashi Kasei Co., Ltd. under the trade name of Micron White 5000S.

(Other Fillers Used for Comparison)

Glass flakes: those having an average grain size of 600 μm and athickness of 2 to 6 μm, product of Nippon Sheet Glass Co., Ltd. underthe trade name of REFG-101.

Glass fibers: 3 mm long chopped strands having a diameter of 13 μm.

Examples 1-8 and Comparative Examples 1-8

The component materials other than fibrous calcium silicate, glassfibers and glass flakes were blended in the ratios shown in Table 1 toprepare the resin compositions, and each resin composition was uniformlymixed up by a tumbler mixer. Then, using a twin-screw extruder (30 mm Φ)having two feed openings, the resin composition was supplied from themain hopper while feeding fibrous calcium silicate, glass fibers andglass flakes from a downstream hopper at a cylinder temperature of 280°C., and the mixture was pelletized.

The thus obtained pellets were injection molded by an injection moldingmachine (cycap M-2 with a clamping force of 75T, mfd. by Sumitomo HeavyIndustries Ltd.) at a cylinder temperature of 280° C. and a moldtemperature of 80° C. to make the ISO multipurpose test pieces. Thesetest pieces were evaluated by the following methods. Results are shownin Table 1.

[Evaluation Methods]

(1) Flexural Modulus

The test pieces were subjected to a three-point bending test accordingto the ISO 178 bending test method.

(2) Flame Retardancy

Flammability at 1.5 mm thickness was tested according to the UL94vertical flammability test.

(3) Self-Tapping Properties

The resin compositions were molded into the test pieces each having acylindrical boss (boss size: 3.5 mm in inner diameter, 2.5 mm in wallthickness and 10 mm in height) by an injection molding machine (mfd. byToshiba Machine Co., Ltd., clamping force: 150T) at a cylindertemperature of 280° C. and a mold temperature of 80° C. A “B” tighteningscrew having a nominal size of 4 mm in diameter and 8 mm in length wasdriven into the boss of each test piece, and the torque that causedbreaking of the boss was measured and designated breaking torque.

(4) Warpage

The resin compositions were molded into the 150 mm×150 mm×20 mm high and2 mm thick box-like test pieces by an injection molding machine (mfd. byToshiba Machine Co., Ltd., clamping force: 150T) at a cylindertemperature of 280° C. and a mold temperature of 80° C. Warpage of thetop portion of each box-like test piece was measured by athree-dimensional measuring machine mfd. by Mitsutoyo Corporation.Measurement was made at 15 points 10 mm away from each other along thecenter line of the top portion, and the maximum amount of fall from thereference line connecting both ends was expressed as warpage.

(5) Abrasion of Mold

The resin compositions were 10,000-shot molded into the test pieces eachhaving a 2 mm-diameter pin erected in a runner by an injection moldingmachine (mfd. by Nissei Plastic Industrial Co., Ltd. at a cylindertemperature of 280° C. and a mold temperature of 40° C. The pins weremade of NAK80 and designed exchangeable, and each pin was replaced withnew one every time the material was changed. Then the diameter of eachpin after 10,000 shot molding was measured by a three-dimensionalmeasuring machine mfd. by Mitsutoyo Corporation, and the difference fromthe pin diameter measured before molding was determined and expressed asthe amount of abrasion.

The smaller the difference of pin diameter before and after molding, theless the abrasion of the mold.

TABLE 1 Example Unit 1 2 3 4 Composition (A-1) PC parts by — — — —weight (A-2) PPE parts by 50 60 50 60 weight (A-3) AS pparts by — — — —weight (A-4) ABS parts by — — — — weight (A-5) PS parts by 50 40 50 40weight (B) Phos- parts by B-1 B-2 B-1 B-2 phoric weight 6 8 6 8 ester(Type) (Amount blended) Fluorine parts by — — — — resin weight (C)Fibrous wt % in 15 20 10 10 calcium the com- silicate position (D) Micawt % in and/or talc the com- (Type) position D-2 D-2 D-3 D-2 (Amount 1510 20 10 blended) Glass flakes wt % in — — — — the com- position Glassfiber wt % in — — — — the com- position Properties Flexural MPa 8,1008,400 7,600 6,000 modulus Flame — V-1 V-1 V-1 V-1 retardancySelf-tapping N · m 1.6 1.5 1.7 Breaking torque Warpage μm 500 560 430490 Mold μm ≦1.0 ≦1.0 ≦1.0 ≦1.0 abrasion Example Unit 5 6 7 8Composition (A-1) PC Parts by — 100 85 85 weight (A-2) PPE parts by 70 —— — weight (A-3) AS parts by — — 15 — weight (A-4) ABS parts by — — — 15weight (A-5) PS parts by 30 — — — weight (B) Phos- parts by phoricweight ester (Type) B-1 B-2 B-1 B-2 (Amount 14 10 12 12 blended)Fluorine parts by — 0.2 0.2 0.2 resin weight (C) Fibrous wt % in 15 2010 10 calcium the com- silicate position (D) Mica wt % in and/or talcthe com- (Type) position D-2/D-3 D-3 D-1 D-1/D-3 (Amount 7.5/7.5 10 1510/10 blended) Glass flakes wt % in — — — — the com- position Glassfiber wt % in — — — — the com- position Properties Flexural MPa 8,0008,300 8,200 8,000 modulus Flame — V-0 V-0 V-1 V-1 retardancySelf-tapping N · m 1.7 2.2 1.8 1.8 Breaking torque Warpage μm 470 420470 410 Mold μm ≦1.0 ≦1.0 ≦1.0 ≦1.0 abrasion

TABLE 2 Comparative Example Unit 1 2 3 4 Composition (A-1) PC parts by —— — — weight (A-2) PPE parts by 50 60 50 70 weight (A-3) AS parts by — —— — weight (A-4) ABS parts by — — — — weight (A-5) PS parts by 50 40 5030 weight (B) Phos- parts by phoric weight ester (Type) B-1 B-2 B-1 B-1(Amount 6 8 6 14 blended) Fluorine parts by — — — — resin weight (C)Fibrous wt % in 30 — — — calcium the com- silicate position (D) Mica wt% in and/or talc the com- (Type) position — D-2 D-3 D-2/D-3 (Amount — 3030 15/15 blended) Glass flakes wt % in — — — — the com- position Glassfiber wt % in — — — — the com- position Properties Flexural MPa 8,5007,900 7,400 7,700 modulus Flame — V-0 V-0 V-1 V-0 retardancySelf-tapping N · m 1.9 0.9 0.9 0.9 Breaking torque Warpage μm 820 400410 410 Mold μm ≦1.0 ≦1.0 ≦1.0 ≦1.0 abrasion Comparative Example Unit 56 7 8 Composition (A-1) PC parts by — 100 85 85 weight (A-2) PPE partsby 70 — — — weight (A-3) AS parts by — — 15 — weight (A-4) ABS parts by— — — 15 weight (A-5) PS parts by 30 — — — weight (B) Phos- parts byphoric weight ester (Type) B-1 B-2 B-2 B-2 (Amount 14 10 12 12 blended)Fluorine parts by — 0.2 0.2 0.2 resin weight (C) Fibrous wt % in — — 152 calcium the com- silicate position (D) Mica wt % in and/or talc thecom- (Type) position — D-3 — D-1 (Amount — 10 — 2 blended) Glass flakeswt % in 15 — 15 — the com- position Glass fiber wt % in 15 — — — thecom- position Properties Flexural MPa 8,000 8,400 8,000 2,900 modulusFlame — V-1 V-0 V-1 V-1 retardancy Self-tapping N · m 1.9 2.3 1.9 1.9Breaking torque Warpage μm 640 710 480 400 Mold μm 3.0 4.0 3.0 ≦1.0abrasion

1. A reinforced thermoplastic resin composition comprising at least anamorphous thermoplastic resin (A), a flame retardant (B), fibrouscalcium silicate (C) and an inorganic material (D) comprising talcand/or mica, wherein the amorphous thermoplastic resin (A) is selectedfrom the group consisting of polycarbonate resin, a mixture ofpolycarbonate resin and another thermoplastic resin, and a mixture ofpolyphenylene ether resin and polystyrene resin; the content of flameretardant (B) being 0.01 to 30 parts by weight based on 100 parts byweight of the amorphous thermoplastic resin (A); the content of fibrouscalcium silicate (C) in said composition being 3 to 30% by weight, andthe content of the inorganic material (D) comprising talc, mica ormixture thereof in said composition being 3 to 30% by weight; whereinthe fibrous calcium silicate (C) is a wollastonite having an initialfiber diameter of 2 to 30 μm and initial fiber length of 20 to 400 μm.2. A reinforced thermoplastic resin composition according to claim 1,wherein the amorphous thermoplastic resin (A) is a polycarbonate resinor a mixture of polyphenylene ether and polystyrene resin.
 3. Areinforced thermoplastic resin composition according to claim 1, whereinthe ratio by weight of fibrous calcium silicate (C) to the inorganicmaterial (D) comprising talc, mica or mixture thereof is (C): (D)=1:10to 10:1.
 4. A reinforced thermoplastic resin composition according toclaim 1, wherein flame retardant (B) is a phosphoric ester compound. 5.A reinforced thermoplastic resin composition according to claim 1,wherein the inorganic material (D) is talc.
 6. A reinforcedthermoplastic resin composition according to claim 1, wherein theinorganic material (D) is mica.
 7. A reinforced thermoplastic resincomposition according to claim 1, wherein the inorganic material (D) isa mixture of talc and mica.
 8. A molded product comprising thereinforced thermoplastic resin composition as defined in claim
 1. 9. Themolded product according to claim 8 having a cylindrical boss or bosses.10. The molded product according to claim 9, wherein the cylindricalboss is of a structure allowing a metal screw to be directly driven intothe boss.